基于动态过渡区调控的4043铝合金激光熔丝增材制造末端缺陷抑制与成形优化

Mitigation of end defects and forming optimization in wire-fed laser additive manufacturing of 4043 aluminum alloy based on dynamic transition zone regulation

  • 摘要:
    目的 该研究旨在探究4043铝合金激光熔丝增材制造过程中单道熔覆形貌控制及末端缺陷抑制方法,分析激光功率、送丝速率和移动速度的耦合作用机制,并提出动态过渡区调控策略。
    方法 通过调控激光功率、送丝速率和移动速度等工艺参数,分析其对熔覆形貌及缺陷的影响规律,提出前、后过渡区协同调控方法,前过渡区采用预热以降低润湿角,后过渡区通过功率递减、移动提速及送丝优化实现丝端主动分离,以抑制末端粘连与塌陷缺陷。
    结果 结果表明,提升激光功率可扩大熔覆宽度并降低高度;送丝速率超过4.5 m/min,易引发未熔合缺陷;移动速度达3 m/min时,瑞利不稳定性诱发驼峰缺陷。经动态过渡区优化后,粘连率显著降低,塌陷深度控制在0.08 mm以内,缺陷抑制效果优于传统方法。
    结论 动态过渡区调控策略可有效抑制4043铝合金激光熔丝增材制造过程中的末端缺陷,提升成形质量,为实现铝合金高效增材制造提供了理论依据与工艺优化方向。

     

    Abstract: Objective This study focuses on controlling the single-track cladding morphology and suppressing end defects in wire-fed laser additive manufacturing of 4043 aluminum alloy. The coupling effects of laser power, wire feeding rate, and travel speed are investigated, and a dynamic transition zone regulation strategy is proposed. Methods By regulating welding parameters such as laser power, wire feeding rate and travel speed, influence of these parameters on cladding morphology and defects is analyzed. A collaborative control method for the front and rear transition zones is proposed, the front transition zone uses preheating to reduce wetting angle, while the rear transition zone uses power reduction, increasing travel speed and wire feeding optimization to achieve active separation of wire tip, thereby suppressing end adhesion and collapse defects. Results Results indicate that increasing laser power expands cladding width while reducing its height. A wire feeding rate exceeding 4.5 m/min tends to induce lack-of-fusion defects, and a travel speed of 3 m/min triggers hump defects due to Rayleigh instability. After optimization of dynamic transition zone, adhesion rate decreases significantly, and collapse depth is controlled within 0.08 mm. Compared to traditional methods, this strategy demonstrates enhanced defect suppression. Conclusion Dynamic transition zone regulation strategy can effectively suppress end defects in wire-fed laser additive manufacturing process of 4043 aluminum alloy and improve forming quality, providing theoretical and process optimization insights for efficient additive manufacturing of aluminum alloy.

     

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